Sterilization of degradable polymeric biomaterials intended for injection presents a formidable challenge. Often, either the polymer backbone or labile crosslinks controlling degradation are adversely affected by commonly used sterilization methods. The purpose of this work was to develop an approach to sterilize tetra-polyethylene glycol hydrogel microspheres (MSs) with -eliminative crosslinks that are destined to be carriers for drug delivery. The approach taken was to acidify the medium to compensate for the base-catalyzed cleavage of linkers at high temperatures. We determined that rates of linker cleavage at pH 4 or below were sufficiently slow as to allow autoclaving and showed that precursor amine-derivatized MSs could withstand autoclaving at pH 4 for at least four cycles of 20 minutes each at 121 • C. Thus, amine-MSs need not be prepared aseptically, but instead can be prepared in a low bioburden environment, and then sterilized by autoclaving before drug attachment.
K E Y W O R D Sbiodegradable hydrogel, drug delivery, half-life extension, microspheres, tetra-polyethylene glycol
INTRODUCTIONWe have developed a general approach for half-life extension of therapeutics, in which a drug is covalently tethered to a long-lived carrier by a linker that slowly cleaves by -elimination to release the native drug (Scheme 1). 1 The cleavage rate of the linker is controlled by the nature of an electron-withdrawing "modulator" (Mod) attached to a carbon containing an acidic C-H bond. After rate-determining proton removal, the intermediate rapidly collapses to provide the free drug. These linkers are not affected by enzymes and are stable for years when stored at low pH and temperature. One carrier we use is a large-pore tetra-polyethylene glycol (PEG) hydrogel polymer. 2-4 These hydrogels-fabricated as uniform 50-μm microspheres (MSs)-are injected subcutaneously (SC) or locally through a small-bore needle where they serve as a depot to slowly release the drug. Importantly, a slower cleaving -eliminative linker is incorporated in crosslinks of these polymers, so gel degradation occurs after drug release. 3,5 Fabrication of tetra-PEG hydrogel MS-drug conjugates is achieved in two stages (Scheme 2). 3,4 Stage 1 involves preparation of amine-derivatized MSs. Here, equimolar amounts of an 8-arm PEG containing 4 amine-and 4 azido-linker end groups and a 4-arm PEG containing cyclooctyne end groups are mixed in a droplet forming device. The azide (A) and cyclooctyne (B) end groups of the PEG prepolymers react within the droplets by strain-promoted alkyne-azide cycloadditions (SPAAC) to form 1,2,3-triazoles and provide homogeneous amine-derivatized tetra-PEG